Transfer Case - AWD: Notes

WARNING: This page is about a different car, the 2004 Mercury Mountaineer and 2004 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Identifying Special Tool(s)

Courtesy of FORD MOTOR CO.

MATERIAL SPECIFICATION

Item	Specification
Silicone Gasket and Sealant F7AZ-19554-EA	WSE-M4G323-A4
MERCON® Automatic Transmission Fluid XT-2-QDX	MERCON®

CAUTION: Discard all seals after removing them.

WARNING: Make sure the special tool lock pin is secure.

Fig 2: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, secure the transfer case to a bench.
Remove the dampener.
If not done previously, remove the drain plug and drain the fluid.

Fig 3: Removing Drain Plug
Courtesy of FORD MOTOR CO.
Index-mark the rear output shaft flange and the upper output shaft.

Fig 4: Marking Rear Output Shaft Flange And Upper Output Shaft
Courtesy of FORD MOTOR CO.
Remove the parts in the order indicated in the following illustration and table.

Fig 5: Dissassembled View Of Transfer Case
Courtesy of FORD MOTOR CO.

Fig 6: Identifying Components For Dissassembled View Of Transfer Case
Courtesy of FORD MOTOR CO.
To assemble, reverse the disassembly procedure.